Linear drive transport system and method

ABSTRACT

A linear drive transport system includes a plurality of fixed tracks and a junction track disposed on a conveyor configured to align the junction track with each of the plurality of fixed tracks. The plurality of fixed tracks and the junction track include one of electromagnetic coils or permanent magnets arranged in series along the respective plurality of fixed tracks and the junction track. In addition, the linear drive transport system includes a plurality of movers configured to move along the fixed tracks and configured to transition between each of the plurality of fixed tracks and the junction track when aligned, wherein the movers comprise the other of the electromagnetic coils or the permanent magnets.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims priority to U.S.application Ser. No. 16/404,186, entitled “LINEAR DRIVE TRANSPORT SYSTEMAND METHOD,” filed May 6, 2019, which is a continuation of U.S.application Ser. No. 15/961,565, entitled “LINEAR DRIVE TRANSPORT SYSTEMAND METHOD,” filed Apr. 24, 2018, now U.S. Pat. No. 10,280,016, issuedMay 7, 2019, which is a continuation of U.S. application Ser. No.15/456,231, entitled “LINEAR DRIVE TRANSPORT SYSTEM AND METHOD,” filedMar. 10, 2017, now U.S. Pat. No. 9,957,119, issued May 1, 2018, which isa continuation of U.S. application Ser. No. 14/563,687, entitled “LINEARDRIVE TRANSPORT SYSTEM AND METHOD,” filed Dec. 8, 2014, now U.S. Pat.No. 9,611,107, issued Apr. 4, 2017; all of which are herein incorporatedby reference in its entirety.

BACKGROUND

The present disclosure is generally directed to linear drive transportsystems and methods. More particularly, present embodiments are directedto systems and methods for conveyance management, including monitoringand control, with a linear drive transport system.

A linear drive or linear motor generally includes an electromagneticdevice that operates to provide motion along a path or “linear motion”rather than the rotary motion typically provided by a standard electricmotor. In operation, a linear drive typically produces electromotiveforce in a conductor by changing a magnetic field about the conductor.Specifically, linear drives generally function based on interactionsbetween electromagnets and permanent magnets. Coils of theelectromagnets can be charged to create magnetic fields that interactwith permanent magnets to provide motion. There are two fundamentallinear drives categories, which may be referred to as moving magnet (orfixed coil) linear drives and moving coil (or fixed magnet) lineardrives. In a moving magnet linear drive, the coils are fixed within atrack or track segments and movers along the track include permanentmagnets. In a moving coil linear drive, permanent magnets are fixedwithin a track or track segments and movers along the track includecoils. Certain functional characteristics of these two categories aredifferent and often play a key role it determining which category toemploy for a particular purpose. For example, moving magnet lineardrives allow for unpowered movers whereas moving coil linear drivesgenerally require that power be provided to the electromagnet on eachmover. As another example, moving coil linear drives are often capableof greater movement precision for the movers than moving magnet lineardrives.

Linear drives are often used in transport systems that facilitatedifferent types of industrial operations. For example, linear drivetransport systems may be utilized to convey products to different areasin a manufacturing or packaging operation. However, due to the nature ofthe interaction between movers and track segments in linear drivesystems, most linear drives include straight or circular tracks. Thishas caused limited employment of linear drives due to a lack ofversatility in traditional arrangements. It is now recognized that it isdesirable to have more versatility in conveyance paths for linear drivesin certain industrial operations.

BRIEF DESCRIPTION

Present embodiments include a linear drive transport system. The systemincludes a plurality of fixed tracks and a junction track disposed on aconveyor configured to align the junction track with each of theplurality of fixed tracks. The plurality of fixed tracks and thejunction track include electromagnetic coils or permanent magnetsarranged in series along the respective plurality of fixed tracks andthe junction track. Further, present embodiments include a plurality ofmovers configured to move along the fixed tracks and configured totransition between each of the plurality of fixed tracks and thejunction track when aligned, wherein the movers comprise the other ofthe electromagnetic coils or the permanent magnets.

Present embodiments also include a shuttle system for a linear drivetransport system. The shuttle system includes a conveyor configured tomove along a path that is transverse to a plurality of linear drivetracks that are configured to transport a linear drive mover in one of amoving magnet configuration or a moving coil configuration. Further, theshuttle system includes a junction track disposed on the conveyor,wherein the junction track is configured to transport the linear drivemover in the same one of the moving magnet configuration or the movingcoil configuration as the plurality of linear drive tracks. Further, theconveyor is configured to align the junction track with at least asubset of the plurality of linear drive tracks to facilitate transfer ofthe linear drive mover there between.

Present embodiments also include a method of positioning movers in alinear drive transport system. The method includes aligning a junctiontrack with a first fixed track of a plurality of fixed tracks by movingthe junction track with a conveyor on which the junction track isdisposed. Further, the method includes impelling at least one moveralong the first fixed track, transitioning the at least one mover fromthe first fixed track to the junction track, aligning the junction trackwith a second fixed track of the plurality of fixed tracks using theconveyor, and transitioning the at least one mover to the second fixedtrack under the influence of electromagnetic force resulting frominteraction between at least one electromagnet coil and at least onepermanent magnet.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a schematic representation of a linear drive transport systemin accordance with present embodiments;

FIG. 2 is a perspective view of a pair of tracks and a shuttle system ina linear drive transport system in accordance with present embodiments;

FIG. 3 is a schematic, perspective view of a linear drive transportsystem incorporating numerous tracks and shuttling systems in accordancewith present embodiments;

FIG. 4 is a schematic, overhead view of a linear drive transport systemincorporating a turntable for a conveyor in accordance with presentembodiments;

FIG. 5 is a schematic, perspective view of a linear drive transportsystem configured to maneuver at least one mover between multiple planesof operation in accordance with present embodiments;

FIG. 6 is a block diagram of a method in accordance with presentembodiments;

FIG. 7 is an overhead view of a portion of a linear drive transportsystem incorporating a tag and a tag reader or sensor in accordance withpresent embodiments; and

FIG. 8 is a perspective view of a mover incorporating a tag reader orsensor in accordance with present embodiments.

DETAILED DESCRIPTION

Present embodiments are directed to linear drive transport systems andcomponents thereof. A linear drive transport system employs lineardrives that utilize principles of electromagnetic propulsion totransport movers along a track. The linear drive transport system mayemploy a moving magnet configuration or a moving coil configuration. Inboth configurations, movers are impelled under the influence ofelectromagnetic force resulting from interaction between twoelectromagnetic fields (e.g., interaction between one or moreelectromagnetic coils and one or more permanent magnets). For example,in a moving magnet configuration, a mover may include an array ofpermanent magnets that are forced along as a result of interactionbetween magnetic fields of the array and magnetic fields generated byelectromagnet coils in a track. Similarly, in a moving coilconfiguration, a mover may include one or more electromagnet coils and atrack may include permanent magnets that cooperate to impel the moveralong the track. In some embodiments, different combinations of magnetsmay be used (e.g., electromagnets alone may be used).

Traditionally, the tracks utilized in linear drive transport systems areessentially configured in a straight line or loop (e.g., oval)configurations. It is now recognized that these traditional trackconfigurations often make it difficult to pass articles (e.g., productsbeing transported) along variable paths and to transfer articles betweenpaths. For example, in traditional configurations, the ability to divertan article from a central path to one of several diverging paths mayrequire the use of pucks and complicated track switching mechanisms,wherein the pucks are movers that are not physically attached to thetrack and thus free to move from a central path to any of severaldiverging paths that extend from the central path. However, this type ofconfiguration may lack sufficient stability and positional accuracy forcertain operations. Further, such diverging paths typically requirepaths that have curves, which can complicate system assembly. Forexample, in a moving magnet configuration, tracks typically compriselaminates that are assembled to form the tracks. If a curved track isdesired, specially designed laminate assemblies may be required, whichit is now recognized can cause substantial inefficiencies in systemmanufacturing and assembly.

Present embodiments are directed to incorporation of at least oneshuttle system with a linear drive transport system to facilitate divertand merge transport operations for movers of the system. FIG. 1 is aschematic representation of a linear drive transport system (LDT system)10 in accordance with present embodiments. The LDT system 10 includes aplurality of shuttle systems 12 that facilitate transfer of a mover body14, which is representative of a central physical structure of one or aplurality of movers 16, between separate tracks 18 of the LDT system 10.Thus, the mover 16 and any associated article (e.g., products disposedon or otherwise engaged by the mover 16) being transported by the LDTsystem 10 may be merged onto a single track from multiple tracks,diverted to separate tracks from a single track, or otherwise maneuveredthroughout a system of tracks (e.g., tracks 18). The mover 16 may bepositioned along any of the various tracks 18 or on any of the variousshuttle systems 12 at certain points during system operation.Accordingly, the mover or movers 16 are schematically represented inFIG. 1 as capable of being positioned at various locations throughoutthe LDT system 10. Likewise, in certain embodiments, each of a pluralityof movers 16 may be positioned at different locations throughout the LDTsystem 10.

The shuttle systems 12 are each illustrated as including one or morejunction tracks 20, which generally operate in the same manner as theplurality of tracks 18 they interact with. That is, the junction tracks20 may employ one of permanent magnets 22 or electromagnet coils 24 tointeract with the other of permanent magnets 22 or electromagnet coils24 in the movers 16 to provide motivation along the tracks 18 andjunction tracks 20 using electromagnetic force. In the illustratedembodiment, the tracks 18 and the junction tracks 20 operate with themovers 16 as a linear drive in a moving magnet configuration.Accordingly, the mover body 14 is illustrated as including the permanentmagnet (e.g., an array of permanent magnets) 22, while the tracks 18 andjunction tracks 20 are illustrated as including the electromagnet coils24. In other embodiments, the mover body 14 may include theelectromagnet coils 24, while the tracks 18 and junction tracks 20include the permanent magnets 22.

Unlike certain fixed tracks (e.g., at least a subset of tracks 18) thatthe shuttle systems 12 interact with, the junction tracks 20 are eachdisposed on a mover 26 of the corresponding shuttle system 12, whereinthe mover 26 is disposed on, coordinates with, or incorporates aconveyor 28 of the corresponding shuttle system 12. In some embodiments,the junction track 20 is disposed on the mover 26 in such a way as to beessentially integral therewith and the junction track 20 basicallyfunctions as both the mover 26 and the junction track 20. In otherembodiments, the junction track 20 is disposed on but delineated asseparate from the mover 26. For example, in one embodiment, the junctiontrack 20 may be disposed on a surface of a conveyor belt, wherein thebelt surface is considered a mover 26 of the shuttle system 12 and anassociated drive mechanism (e.g., chain) of the conveyor belt isconsidered the conveyor 28 of the shuttle system 12 in accordance withpresent embodiments. However, the conveyor 28 may also include a rotarytable, a linear drive, or other types of conveyance mechanisms inaccordance with present embodiments. For example, the mover 26 on whichthe junction track 20 is disposed may be a mover 26 of a linear drivesystem that is in a moving magnet configuration or a moving coilconfiguration and functioning as the conveyor 28. More specifically, insuch an embodiment, the mover 26 and an associated track of the lineardrive system may cooperate to function as the conveyor 28. In someembodiments, the junction track 20 may be disposed on the mover 26 in amanner that makes it integral with the mover 26 such that a singlecomponent is both the junction track 20 and the mover 26. As indicatedabove, the shuttle systems 12 may incorporate more than one junctiontrack 20 on each mover 26. Further, multiple movers 26 may be positionedon one conveyor in a shuttle system 12. Further still, a single shuttlesystem 12 may include multiple conveyors 28.

The movers 26 and conveyors 28 of the shuttle systems 12 that maneuverthe junction tracks 20 are configured to align the respective junctiontracks 20 with one of a plurality of other tracks (e.g. fixed tracks 18)to facilitate transfer of movers 16 there between. Accordingly, themovers 16 (and articles being moved) can be maneuvered to differentlocations throughout the LDT system 10 for processing or warehousing.For example, certain tracks 18 may be considered components ofparticular system modules 30 and these system modules 30 may includecertain process features 32 that the movers 16 interact with bytraveling along specific tracks in the system module 30. Specifically,for example, the mover 16 may be directed along particular tracks 18 inthe system module 30 such that it passes through a process feature 32(e.g., an oven, a rinse chamber, a deposition chamber, a packagingrobot) and facilitates processing of an article being carried by themover 16. The mover 16 may be directed along a particular path 18through such a process feature 32 and then transitioned by a shuttlesystem 12 to a different path 18 in the system module for interactionwith a different process feature 32. In other embodiments, such featuresmay be utilized to transfer articles to particular areas forwarehousing.

With the foregoing processing and warehousing techniques in mind, it isnow recognized that it is also desirable to facilitate determining whereparticular movers 16 or related articles currently reside and where theyhave previously been within the LDT system 10. It may be desirable todetermine where a particular mover 16 should be directed, where itpreviously resided, or where it is currently stored or located.Accordingly, in addition to using a position feedback board 34, which isused for detection and control in linear drives, present embodiments maymonitor the mover 14 using tags 36 and tag detectors 38. A tag 36 (e.g.,a bar code, RFID tag, text capable of being identified by OpticalCharacter Recognition (OCR)) may be disposed on the mover 14 (orarticles being moved) and detected by the tag detectors 38 positionedthroughout the LDT system 10. The detectors 38 may be positionedproximate exits and entries to tracks 18 and junction tracks 20. Forexample, the detectors 38 may include bar code readers, an OCR system,or RFID detectors positioned adjacent, positioned over, or integratedinto the tracks 18 or junction tracks 20 in an orientation thatfacilitates detection of the tags 36 as they pass near the movers 16.Information detected or accumulated in this way may be communicated to asupervisory controller 40 to facilitate tracking of mover locationswithin the system, determining where movers 16 should proceed forfurther processing, tracking batches and serialization, and so forth.The supervisory controller 40 may interact with the position feedbackboard 34 to further identify or confirm mover locations and tofacilitate positional control.

FIG. 2 is a perspective view of a portion of an LDT system 10 inaccordance with present embodiments. The LDT system 10 of FIG. 2includes a pair of fixed tracks 18 and a shuttle system 12 configured tomaneuver movers 16. In the illustrated embodiment, the tracks 18 arelinear drive tracks configured for operation in a moving magnetconfiguration. Further, the junction track 20 is essentially identicalto a segment of the fixed tracks 18 but positioned on (e.g., integralwith) a mover 26 of a linear drive configured for operation in a movingcoil configuration. Indeed, the shuttle system 12 of FIG. 2 includes aconveyor 28 defined by the mover 26 supporting the junction track 20 anda rail 50 including a series of embedded permanent magnets 52. Theconveyor 28 further includes a tether 54 for providing power to themover 26 from a corresponding power supply 56. In the illustratedembodiment, the junction track 20 is in the process of being alignedwith the one of the fixed tracks 18 on which the movers 16 arepositioned, as illustrated by arrow 60. Once the conveyor 28 properlyaligns the junction track 20 and the track 18, at least one of themovers 16 may be transitioned onto the junction track 20 from the track18. More specifically, a mover 16 may be impelled from the fixed track18 onto the junction track 20 using electromagnetic forces generatedusing principles of induction. To achieve very precise alignment betweenthe junction track 20 and other tracks 18, it may be desirable to use amoving coil configuration for the conveyor 28 (as illustrated), whichmay facilitate more finely controlled positioning than is typicallyavailable using a moving magnet linear drive configuration. However, inother embodiments, different configurations may be employed.

Like the fixed track 18 from which the junction track 20 receives themover 16, the junction track 20 may also coordinate with the mover 16 toimpel it onto the other track 18 after the conveyor 28 repositions thejunction track 20 into alignment therewith. In some embodiments, othertracks 18 may already be in alignment with the track 18 from which themover 16 is being transferred such that the junction track 20 operatesmuch like a gateway. Further, in some embodiments, segments of track 18may be utilized as places for parking movers 16 until it is desirable toreposition them. It should be noted that the conveyor 28 that maneuversthe junction track 20 generally operates to move the junction track 20in a direction that is transverse to the direction a mover 16 willtravel on the tracks 18 (e.g., fixed tracks) that the junction track 20is interacting with. This may include moving in one or more directions(e.g., horizontally, vertically, angled) relative to the tracks 18. Inthe illustrated embodiment, the tracks 18 and shuttle system 12 arelinear and positioned cross-wise to one another. Further, the system 10is configured such that movers 16 may pass from one of the tracks 18onto the junction track 20 by passing over a side of the junction track20 facing the one of the tracks 18 and then exit onto one of the tracks18 by passing across the same side of the junction track 20.

FIG. 3 is a schematic, perspective view of one embodiment of the LDTsystem 10 in accordance with the present disclosure. The LDT system 10of FIG. 3 includes a plurality of fixed tracks 18 that may coordinatewith movers 16 in a moving magnet orientation. Similarly, the shuttlesystems 12 in FIG. 3 include junction tracks 20 that coordinate with themovers 16 in a moving magnet configuration to facilitate transfer of themovers 16 between the tracks 18. In other embodiments, differentconfigurations may be used. For example, combinations of moving magnetand moving coil configurations may be employed. Further, the shuttlesystems 12 may employ any of various and mixed configurations inaccordance with present embodiments. For example, some or all of theshuttle systems 12 in the embodiment illustrated by FIG. 3 may employ amoving magnet linear drive system, wherein the junction track 20 is themoving magnet while also being a electromagnetic track for the movers16. As another example, some or all of the shuttle systems 12 mayinclude traditional belt systems or turntables as components formaneuvering the junction track 20, which operates with the movers 16 ina linear drive configuration (e.g., moving magnet or moving coilconfiguration).

Specifically, in the illustrated embodiment, four of the tracks 18, asindicated by reference numeral 70, are positioned between two inner setsof shuttle systems 12, which are indicated by reference numeral 72.Additional tracks 18, as indicated by reference numeral 74, arepositioned outside of the inner shuttle systems 72 and between outershuttle systems 12, as indicated by reference numeral 76. Further, oneof the fixed tracks 18, as indicated by reference numeral 78, provideswhat may be considered a bypass around the other tracks 70, 74 anddirectly between the outer shuttle systems 76. The four tracks 70 may beconfigured to facilitate interaction between payloads (articles beingcarried by movers 16 positioned on the tracks 70) and certain processfeatures 32 (not shown) configured to perform acts on the payloads. Theinner shuttle systems 72 may facilitate transferring the movers 16between the various tracks 18 and to the outer shuttle systems 76. As anexample, certain products may be moved along one of the tracks 70 in afirst direction, transferred to a second of the tracks 70 by an innershuttle system 72, and then moved along the second of the tracks 70 in adirection opposite to the first direction. This may be done to pass thepayloads through certain process features 32 to achieve an end goal forthe products. The fixed track 78 may be used to bypass all of the fourtracks 70, which may allow for processing payloads along each of thefour tracks 70 in the same direction. Some of the tracks 18, such as theadditional tracks 74 may be utilized as holding areas or areas forparking movers 16 during certain phases or transitions in processing.

The embodiment illustrated by FIG. 3 generally illustrates pathways(tracks 18) that are aligned within the same plane and in parallel. Itshould be noted that geometric terms such as “parallel” and“perpendicular” are presently utilized to facilitate general discussionof geometric orientations and should not be understood as requiring aprecise mathematical relationship that would be essentially unattainablein a practical application. Because the tracks 18 are in parallel, theshuttle systems 12 of FIG. 3 operate to move the junction tracks 20 in adirection perpendicular to the tracks 18. This may be beneficial andpresent embodiments include systems wherein only tracks 18 in parallelarrangements or parallel and perpendicular arrangements or utilized tofacilitate transfer between tracks using operations along straightlines. However, in other embodiments, the junction tracks 20 may bemoved in other manners to traverse the tracks 18 and facilitatetransitioning of movers 16 to other tracks. Further, in someembodiments, the tracks 18 may not be straight lines but curved lines.For example, FIG. 4 illustrates a schematic, overhead view of a shuttlesystem 12 interacting with three tracks 18 that may include curvedportions. In the illustrated embodiment, the shuttle system 12 includesa turntable 82 that rotates (as indicated by arrow 84) about an axis 86such that the junction track 20 can be aligned with each of the tracks18. Thus, the mover 16 can be received onto the junction track 20, thejunction track 20 can be repositioned by the turntable 82 into alignmentwith another of the tracks 18, and the mover 16 can be transitioned tothe other track 18. The force used to transition the mover 16 from thetrack 18 to the junction track 20 and from the junction track 20 to thetrack 18 may be generated from interactions between magnets andelectromagnets, as discussed above. In the illustrated embodiment, theshuttle system 12 is configured such that the mover 16 enters thejunction track 20 from a particular side of the junction track 20 andexits from the same side of the junction track 20.

FIG. 5 is a schematic, perspective view of the LDT system 10 inaccordance with and embodiment of the present disclosure. The embodimentillustrated in FIG. 5 includes a first track group 102 arranged in afirst plane of operation, a second track group 104 arranged in a secondplane of operation, a dual-axis shuttle system 106, a mover 16supporting an article 108, and a supervisory control system 110. Themover 16 may be configured to physically attach with the various tracks18 and the junction track 20 (e.g., a carriage with engagement arms andwheels) or configured to sit on top of the various tracks 18 and thejunction track 20 (e.g., a puck that moves along a path withoutphysically coupling). The dual-axis shuttle system 106 includes avertical linear drive 112 and a horizontal linear drive 114. Theselinear drives 112, 114 may operate in a moving magnet or moving coilconfiguration. The dual-axis shuttle system 106 is configured tofacilitate transfer of the mover 16 and any payload it is carrying(e.g., the article 108) within and between the first and second trackgroups 102, 104. In the illustrated embodiment, this is achieved bysupporting the junction track 20 on a mover 116 disposed on a horizontaltrack 118 of the horizontal linear drive 114, which is supported by amover 120 on a vertical track 122 of the vertical linear drive 112.Specifically, the vertical linear drive 112 includes the vertical track122 and the mover 120, and the horizontal linear drive 114 includes thehorizontal track 118 and the mover 116. When the mover 16 (and/or thearticle 108) is positioned on the junction track 20, the vertical lineardrive 112 enables transport of the mover 16 along a vertical axis, asindicated by arrow 132, while the horizontal drive 114 enables transportof the mover 16 along a horizontal axis, as indicated by arrow 134. Inother embodiments, the vertical and horizontal linear drives 112, 114may include other types of conveyors (e.g., a chain conveyor, a beltconveyor, a rotary table). In some embodiments, this may include the useof multiple vertical and horizontal linear drives 112, 114, which mayuse the same vertical track 122 or multiple horizontal tracks 118 on thesame mover 120. Further, in other embodiments, different configurationsmay facilitate transfer of the mover 16 along an angled or curved axisand certain tracks 18 may include curves. For example, in someembodiments, the vertical track 122 may be a vertical segment of a looptrack.

Present embodiments may include the position feedback board 34, whichmay represent a plurality of such boards and encoder systems, to allowfor control and monitoring of paths by representing each mover 16disposed on a track 18 as a linear axis in a control system. Thefeedback board 34 may be configured to employ magnetic feedback createdby the interaction of movers and track segments to achieve this trackingand control function. Transfer from one track 18 to a junction track 20could be handled by commanding an axis (a mover 16) to the end of thetrack 18 on which it is disposed after aligning the end of the track 18with the junction track 20. At the end of the track 18, the axis wouldbe identified in the encoder system of the beginning of the junctiontrack 20 and the axis could be commanded to transfer from the track 18to the junction track 20.

The ability to move articles 108 with movers 16 into differentoperational planes and in different directions with the shuttle systemor systems 12 and tracks 18 may facilitate numerous different industrialprocesses, including processing and warehousing operations. Indeed,present embodiments are directed to smart warehousing and trackingoperations for certain processes. For example, the embodimentillustrated by FIG. 5 includes the supervisory controller 110, whichcoordinates with sensors 152, which may represent tag detectors 38, thatare disposed proximate entries/exits to the tracks 18 and the junctiontrack 20. The sensors 152 may communicate, via a network (e.g., awireless network), with the supervisory controller 110 to monitor thelocation of movers 16 and/or articles 108. For example, certain articles108 or movers 16 may include identifying features (e.g., bar code orRFID tags) that can be detected by the sensors 152. Information relatedto the location of the sensors 152 and corresponding detection of aparticular tag (e.g., tag 36) can be relayed to the supervisorycontroller 110.

The supervisory controller 110, which may represent multiplecontrollers, includes one or more memories 202 (e.g., a hard drive orother non-transitory computer-readable medium) and processors 204. Thesupervisory controller 110 may be configured to employ an overlordabstraction or virtualization of the LDT system 10 to facilitate smartwarehousing, serialization, process management, and so forth. Thisvirtualization may be achieved by employing a software object on thecontroller 110 or on a separate device with a memory that is incommunication with the supervisory controller 110. The supervisorycontroller 110 may be configured to determine which paths (e.g., tracks18) are available (e.g., include space that can be utilized) anddistribute movers 16 to maximize throughput. This may facilitate removalof certain paths from operation for maintenance purposes while utilizingavailable paths to make up for the absence of the path being repaired.

In operation, in addition to the tracking provided by the feedback board34, present embodiments utilize the supervisory controller 110 and thesensors 152 to keep track of mover identities and/or article identities(tag IDs) as they move throughout the LDT system 10. This includestracking articles 108 as they are stored at certain locations (e.g., ina warehouse). The sensors 152 may be configured to read bar codes, RFIDor other identification features or tags to determine the identificationof a particular article 108 or mover 16. Using such information, thesupervisory controller 110 may provide a visual display on a HumanMachine Interface (HMI) representing where each mover 16 and/or article108 is physically located within the LDT system 10. In some embodiments,the supervisory controller 110 may store tag IDs and an associate batchIDs in a database with details of production for each associated batchfor historical analysis purposes. Such a database, which may be storedin the memory 202, could be used to analyze and determine certain thingsabout process operation and system components. For example, the databasecould be analyzed to determine which paths of the LDT system 10 needmaintenance or to determine details about a batch based on productspecifications. The batch ID could be scanned at the same time with asame or different system as the tag identification system (e.g., thesensors 152) used for the movers and/or articles 108. Batch IDs could bedigitally maintained and/or printed on production features (e.g., aproduction tray) as a visual identification for users (e.g.,technicians) of the system. This would facilitate verification ormatching of manufactured or processed products with production toolingthat was utilized in its manufacture or processing.

FIG. 6 is a block diagram of a method 300 of positioning movers in a LDTsystem in accordance with present embodiments. The method 300 includesaligning (block 328) a junction track with a first fixed track of aplurality of fixed tracks by moving the junction track with a conveyoron which the junction track is disposed. The method 300 also includesimpelling (block 330) at least one mover along the first fixed track,transitioning (block 332) the at least one mover from the first fixedtrack to the junction track, aligning (block 334) the junction trackwith a second fixed track of the plurality of fixed tracks using theconveyor, and transitioning (block 336) the at least one mover to thesecond fixed track under the influence of electromagnetic forceresulting from interaction between at least one electromagnet coil andat least one permanent magnet. The method 300 also includes generating(block 338) the electromagnetic force using interactions between anarray of permanent magnets in the at least one mover and a series ofelectromagnet coils in the first fixed track and the junction track orgenerating the electromagnetic force using interactions between thearray of permanent magnets in the at least one mover and a portion ofthe series of electromagnet coils in the second fixed track. Further,the method 300 may include performing (block 342) a smart warehousing orprocess tracking operation by monitoring a tag on the at least one moverwith tag detectors positioned proximate at least the first and secondfixed tracks and communicating with a supervisory control system.

As discussed above, present embodiments may utilize tags and tag sensorsto track articles 108 and/or movers 16 to facilitate process managementoperations (e.g., smart warehousing). In some embodiments, this includesincorporating respective tags and sensors into the track, movers, andarticles. In accordance with present embodiments, this may be done inspecific ways to facilitate operation. For example, FIG. 7 illustratesan overhead, schematic view of a moving magnet system in accordance withpresent embodiments. A mover 16 is illustrated traversing a track 18,which includes a plurality of coils 402. The mover 16 includes a body 14that spans the width of the track 18 and engages it on opposite sides404, 406 with wheel sets 408, 410. The feedback board 34 represented asresiding under the coils 402 may operate to detect and facilitatecontrol of positional characteristics of the mover 16 relative to thetrack 18. To supplement this, a sensor 412 is integrated into the track18 and positioned to detect a tag 414 integrated with or attached to themover 16. Specifically, the tag 414 and the sensor 412 are positionedsuch that when the mover 16 traverses the track 18, the tag 414 can beread by the sensor 412. In other embodiments, the tag 414 and the sensor412 may be positioned oppositely. That is, the tag 414 may be integratedwith or attached to the track 18 and the sensor 412 may be coupled withthe mover 16. For systems wherein it is preferable to provide power tothe sensor 412 via the track 18, the illustrated embodiment may beutilized.

In yet other embodiments, it may be useful to include a reader on themover 16 to facilitate identification of articles 108 being transported,as illustrated in FIG. 8. Specifically, FIG. 8 illustrates a mover 16incorporating a sensor 412 (e.g., a barcode reader or RFID reader) thatis configured to read a tag 414 disposed on an article 108 that is beingtransported by the mover 16. In the illustrated embodiment, the mover 16includes a carriage body 14 that is configured to physically engage atrack 18 with two wheel sets 408, 410 that are respectively positionedon a central body 502 and an extension 504 from an arm 506 of the body14. It should be noted that the illustrated mover 16 is configured foroperation in a moving magnet system, as is clear from the inclusion of amagnet array 508. However, other embodiments may be configured formoving coil operation. The sensor 412 may include integral electronics510 (e.g., a power source, communication device) that facilitateoperation. For example, the electronics 510 may include a battery andcommunication features that facilitates wireless communication with thesupervisory system 110. Also, in the embodiment illustrated by FIG. 8,the mover 16 includes tags 414 that facilitate identification of themover 16 by other system sensors 152 that are disposed off of the mover16.

While only certain features of present embodiments have been illustratedand described herein, many modifications and changes will occur to thoseskilled in the art. It is, therefore, to be understood that the appendedclaims are intended to cover all such modifications and changes as fallwithin the true spirit of the disclosure.

1. A linear drive transport system, comprising: a first plurality oftracks substantially aligned within a plane; a first junction trackdisposed on a first conveyor configured to align the first junctiontrack with each of the first plurality of tracks, wherein the firstconveyor is disposed on a first side of the first plurality of tracks; asecond plurality of tracks substantially aligned within the plane; and asecond junction track disposed on a second conveyor, wherein the secondconveyor is disposed on a second side of the first plurality of tracksopposite relative to the first side, wherein the second conveyor isconfigured to align the second junction track with each of the firstplurality of tracks and each of the second plurality of tracks; and aplurality of movers configured to move along each of the first pluralityof tracks and the second plurality of tracks, wherein the plurality ofmovers is configured to transition between each of the second pluralityof tracks and the second junction track when aligned; wherein the secondjunction track is configured to receive a mover of the plurality ofmovers from a first track of the first plurality of tracks and to impelthe mover onto a second track of the second plurality of tracks afterbeing repositioned into alignment with the second track by the secondconveyor.
 2. The system of claim 1, wherein each of the first pluralityof tracks, the second plurality of tracks, the first junction track, andthe second junction track comprise one of electromagnetic coils orpermanent magnets arranged along the first plurality of tracks, thesecond plurality of tracks, the first junction track, and the secondjunction track.
 3. The system of claim 2, wherein the plurality ofmovers comprise the other of the electromagnetic coils or the permanentmagnets.
 4. The system of claim 1, wherein the first conveyor comprisesa transverse-oriented linear drive configured to move the first junctiontrack along a path transverse to the first plurality of tracks and toalign with at least one additional track arranged outside of alignmentwith the first plurality of tracks.
 5. The system of claim 1, comprisinga third junction track disposed on a third conveyor, wherein the thirdconveyor is disposed on a different side of the second plurality oftracks relative to the second conveyor, wherein the third conveyor isconfigured to align the third junction track with each of the secondplurality of tracks and a bypass track.
 6. The system of claim 5,wherein the bypass track is configured to bypass the first conveyor andthe second conveyor.
 7. The system of claim 5, wherein the bypass trackis configured to align with a fourth junction track disposed on a fourthconveyor configured to align with the bypass track and each of a thirdplurality of tracks disposed between the fourth conveyor and the firstconveyor.
 8. The system of claim 5, wherein the bypass track is disposedin a different plane relative to the plane.
 9. The system of claim 1,wherein the first conveyor comprises a magnet linear drive and the firstjunction track is disposed on a shuttle mover associated with the magnetlinear drive.
 10. The system of claim 1, comprising a sensor disposed onthe first junction track, wherein the sensor is configured to identify arespective mover of the plurality of movers impelled on the firstjunction track.
 11. The system of claim 1, wherein the plurality ofmovers is configured to transition between each of the first pluralityof tracks and the first junction track when aligned by entering thefirst junction track from the second side of the first junction trackand exiting the first junction track from the first side of the firstjunction track.
 12. A linear drive transport system, comprising: a firstshuttle system; and a second shuttle system comprising: a firstconveyor; a second conveyor; and a bypass track characterized by alength equal to that of the first shuttle system to permit a moverimpelled from the first conveyor to the bypass track to travel to thesecond conveyor via the bypass track without being impelled using thefirst shuttle system, wherein the mover is configured to be impelledfrom the first conveyor to the bypass track based at least in part on anelectromagnetic force resulting from an interaction between at least oneelectromagnet coil and at least one permanent magnet.
 13. The lineardrive transport system of claim 12, wherein the first shuttle systemcomprises: a first plurality of tracks substantially aligned within aplane; a first junction track disposed on a third conveyor configured toalign the first junction track with each of the first plurality oftracks, wherein the third conveyor is disposed on a first side of thefirst plurality of tracks; a second junction track disposed on a fourthconveyor, wherein the second conveyor is disposed on a second side ofthe first plurality of tracks opposite relative to the first side,wherein the second conveyor is configured to align the second junctiontrack with each of the first plurality of tracks; and a plurality ofmovers comprising the mover, wherein each of the plurality of movers isconfigured to move along each of the first plurality of tracks, andwherein the plurality of movers is configured to transition between eachof the first plurality of tracks and the first junction track or thesecond junction track when aligned.
 14. The linear drive transportsystem of claim 13, wherein the mover is configured to be impelled fromthe first junction track to the bypass track and from the bypass trackto the a third junction track disposed on the second conveyor withoutbeing impelled from the second junction track.
 15. The linear drivetransport system of claim 12, wherein the first shuttle system comprisesa plurality of tracks and a curved track.
 16. The linear drive transportsystem of claim 12, wherein the length of the bypass track equals alength of the first shuttle system, and wherein the bypass track ends atthe first conveyor and the second conveyor.
 17. A method of positioningmovers in a liner drive transport system, comprising: aligning a firstjunction track of a first conveyor to a first track of a first pluralityof tracks aligned in a plane; impelling a mover along the first track,thereby transitioning the mover from the first track to the firstjunction track; aligning the first junction track to a second track of asecond plurality of tracks aligned in the plane; impelling the moveralong the first junction track, thereby transitioning the mover from thefirst junction track to the second track; aligning a second junctiontrack of a second conveyor to the second track; impelling the moveralong the second track, thereby transitioning the mover from the secondtrack to the second junction track; aligning the second junction trackwith a bypass track having a length at least equal to a sum of a lengthof the first junction track, a length of the first track, and a lengthof the second track; and impelling the mover along the second junctiontrack, thereby transitioning the mover from the second junction track tothe bypass track, wherein the mover bypasses the first track and thefirst conveyor by impelling the mover along the bypass track.
 18. Themethod of claim 17, comprising: aligning a third junction track with thebypass track; and impelling the mover along the bypass track, therebytransitioning the mover from the bypass track to the third junctiontrack, wherein the third junction track is configured to align with thefirst track.
 19. The method of claim 17, wherein impelling the moveralong the first track comprises applying an electromagnetic forceresulting from an interaction between at least one electromagnet coiland at least one permanent magnet.
 20. The method of claim 17,comprising performing an automated warehousing operation by monitoring atag on the mover with one or more tag detectors positioned on the bypasstrack and communicating with a supervisory control system to facilitateprocess management operations.